Die cast furnace

ABSTRACT

A die cast furnace system is provided, wherein the system includes a microwave energy source and coupler element operably associated therewith. The microwave energy source (e.g., a microwave generator and the like) is selectively operable to heat the coupler element so as to at least partially melt an amount of metal (e.g., aluminum and the like) contained therein. When the metal approximately attains half of its melting point, the microwave energy source is selectively operable to directly heat the metal so as to substantially fully melt the metal. The coupler element can comprise a crucible, such as those constructed of a ceramic material (e.g. silicon carbide and the like).

CROSS-REFERENCE TO RELATED APPLICATION

The instant application claims priority to U.S. Provisional PatentApplication Ser. No. 60/578,583 filed Jun. 10, 2004, the entirespecification of which is expressly incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to die cast furnaces and moreparticularly to die cast furnaces employing microwave generators thatare selectively operable to heat a coupler element and the contentscontained therein.

BACKGROUND OF THE INVENTION

The use of gas and/or oil powered die cast furnaces to melt and/or moldmetallic materials, such as aluminum, other metals such as zinc, silver,and gold, and alloys thereof, are generally well known in the art.Recently, it has been proposed to use microwave energy to melt and/ormold certain types of metallic materials. However, because of theparticular difficulties (e.g., arcing and the like) of using microwaveenergy to heat these metallic materials, as well as the need tocarefully control the processing parameters during the heating process,conventional die cast furnaces are generally not well-suited for thesetypes of heating, melting and/or molding operations.

Accordingly, there exists a need for new and improved die cast furnacesystems, wherein the systems include microwave generators that areselectively operable to heat coupler elements and materials containedtherein.

SUMMARY OF THE INVENTION

In accordance with the general teachings of the present invention, a newand improved die cast furnace system is provided.

In accordance with a first embodiment of the present invention, a newand improved die cast furnace system is provided, wherein the systemincludes a microwave energy source operably associated therewith,wherein the die cast furnace is selectively operable to at leastpartially melt an amount of metal contained therein.

In accordance with a second embodiment of the present invention, a newand improved die cast furnace system is provided, wherein the systemincludes a microwave energy source and coupler element operablyassociated therewith, wherein the die cast furnace is selectivelyoperable to at least partially melt an amount of metal containedtherein.

In accordance with a third embodiment of the present invention, a newand improved die cast furnace system is provided, wherein the systemincludes a microwave energy source and coupler element operablyassociated therewith, wherein the microwave energy source is selectivelyoperable to heat the coupler element so as to at least partially melt anamount of metal contained therein, wherein when the metal approximatelyattains half of its melting point, the microwave energy source isselectively operable to directly heat the metal so as to substantiallyfully melt the metal.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 illustrates an elevational view of a die cast furnace system, inaccordance with the generally teachings of the present invention;

FIG. 2 illustrates a partial sectional view of a die cast furnacesystem, in accordance with a first embodiment of the present invention;

FIG. 3 a illustrates a plan view of a crucible member, in accordancewith a second embodiment of the present invention;

FIG. 3 b illustrates a sectional view of the crucible member depicted inFIG. 3 a, in accordance with a second embodiment of the presentinvention;

FIG. 4 a illustrates a plan view of a first insulating member, inaccordance with a third embodiment of the present invention;

FIG. 4 b illustrates a sectional view of the first insulating member, inaccordance with a third embodiment of the present invention;

FIG. 5 a illustrates a plan view of a second insulating member, inaccordance with a fourth embodiment of the present invention;

FIG. 5 b illustrates a sectional view of the second insulating memberdepicted in FIG. 5 a, in accordance with a fourth embodiment of thepresent invention;

FIG. 6 illustrates a detailed view of an optional microwave splittersystem, in accordance with a fifth embodiment of the present invention;and

FIG. 7 illustrates a partial sectional view of an alternative die castfurnace system, in accordance with a sixth embodiment of the presentinvention.

The same reference numerals refer to the same parts throughout thevarious Figures.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

Referring to the Figures generally, and FIG. 1 specifically, the diecast furnace system of the present invention is generally shown at 10.The system 10 preferably includes a furnace portion 12 and a microwavegenerator system 14. The furnace portion 12 preferably includes a potportion 16 and a lid portion 18.

The pot portion 16 preferably includes a pot member 20 that can beconfigured in any number of shapes, such as round, oval, square,rectangular, and the like. The pot member 20 can be constructed of anynumber of suitable materials, including but not limited to metallicmaterials, and more preferably, steel. Referring specifically to FIG. 2,the pot member 20 preferably includes an area defining a chamber 22formed therein, wherein the chamber includes an open end 24 in proximityto a top surface 26 thereof. The chamber 22 can be configured in anynumber of shapes, such as round, oval, square, rectangular, and thelike. Additionally, the pot member 20 may be provided with a pluralityof feet members 28 located on a bottom surface 30 thereof.

The lid portion 18 preferably includes a lid member 32 and a lidadjustment system 34. The lid member 32 can be configured in any numberof shapes, such as round, oval, square, rectangular, and the like. Thelid adjustment system 34 preferably includes a lever system 36 forpreferably raising and lowering the lid member 32, as well as theability to keep the lid member 32 is a fixed stationary raised position(e.g., with the aid of a pneumatic cylinder system). The lid portion 18is preferably operable to cover the open end 24 of the pot portion 16.Accordingly, the lid member 32 is preferably compatible with the openend 24 so as to ensure that the lid member 32 is operable tosubstantially seal off the open end 24 from the outside environment.

The furnace portion 12 of the present invention can be readilycommercially obtained from McEnglevan Industrial Furnace Co. (Danville,Ill.) under model numbers DO-300, DO-600, DO-1000, DO-1500, and/orDO-2000.

In accordance with a preferred embodiment of the present invention, acoupler element such as a crucible 38 is preferably operable to beselectively disposed within the chamber 22. The crucible 38 ispreferably comprised of silicon carbide or the like, and is operable toabsorb heat from a heat source, such as but not limited to a microwavegenerator. Referring specifically to FIGS. 2-3 b, the crucible 38 can beconfigured in any number of shapes, such as round, oval, square,rectangular, and the like.

In order to prevent heat from escaping the crucible 38, it is preferredto employ insulating material around the crucible 38. In accordance witha preferred embodiment of the present invention, a plurality ofinsulating bricks 40, such as those comprised of high alumina material,are preferably disposed upon the bottom surface 42 of the chamber 22.The bricks 40 not only provide an insulation function, but also aid instabilizing the bottom surface 44 of the crucible 38 within the chamber22.

In accordance with another preferred embodiment of the presentinvention, an amount of bulk insulating material 46, such as thatcomprised of bulk alumina material, is preferably disposed about theside surfaces 48 of the crucible 38. The bulk material 46 not onlyprovides an insulation function, but also aids in stabilizing the sidesurfaces 48 of the crucible 38 within the chamber 22.

In accordance with still another preferred embodiment of the presentinvention, one or more insulating members 50, 52, such as that comprisedof bulk alumina material, are preferably disposed about the sidesurfaces 54, 56 of the chamber 22. Referring specifically to FIGS. 4 a-5b, the insulating members 50, 52, can be configured in any number ofshapes, including but not limited to boards, squares, rectangles,circles, ovals, and the like. Additionally, the insulating members 50,52, 54, 56 can be configured to be concentrically disposed within oneanother in a nesting fashion. The insulating members 50, 52, not onlyprovide an insulation function, but also aid in stabilizing the bulkinsulating material 46 alongside the side surfaces 48 of the crucible 38within the chamber 22. The insulating members 50, 52, can also becomprised of materials that possess different insulating and/ordielectric properties so as to provide various insulation performanceproperties within the chamber 22. The insulating members 50, 52, of thepresent invention can be readily commercially obtained from RathPerformance Fibers, Inc. (Wilmington, Del.) under model numbers KVS 124and/or KVS 125. Additionally, the internal area of the lid member 32 canbe provided with an insulating material, such as but not limited to KVS124.

The exact sequence of loading the crucible 38 and the previouslydescribed insulation materials is generally known in the art and willnot be described in detail herein. Once all of these components areproperly situated within the chamber 22, the material to be processed(e.g., melted) in the crucible 38 can preferably be loaded therein. Thematerials intended to be used in conjunction with the present invention,are generally comprised of metallic materials, such as but not limitedto aluminum, zinc, silver, gold, and the like, including alloys thereof.

In accordance with a preferred embodiment of the present invention, amicrowave generator 58 is preferably operably associated with thefurnace portion 12. The microwave generator 58 can be physicallyassociated with the furnace portion 12 (e.g., disposed within the bodyof the furnace portion 12), or alternatively, may be located outside ofthe body of the furnace portion 12. Without being bound to a particulartheory of the operation of the present invention, the intended purposeof the microwave generator 58 is to provide microwave energy to thefurnace portion 12 so as to provide a heat source for melting thematerials contained within the crucible 38.

The microwave generator 58 is preferably in communication with thechamber 22, the crucible 38 and/or the materials contained within thecrucible 38, such that the microwave energy produced by the microwavegenerator 58 is operable to be transmitted, through any guide, conduit,tube, pipe, wire, cable, and the like to the chamber 22, the crucible 38and/or the materials contained within the crucible 38.

Referring specifically to FIG. 6, in order to provide a uniform heatingfunction, the microwave generator system 14 is preferably provided withan optional splitter system 60 (alternatively, a rotating reflector orstirrer can be employed) operably associated with the microwavegenerator 58 that is selectively operable to substantially uniformlydistribute the microwave energy about the chamber 22, the crucible 38and/or the materials contained within the crucible 38.

Referring specifically to FIG. 7, an alternative die cast furnace systemis shown generally at 100, in accordance with an alternative embodimentof the present invention. The system 100 is similar to the system 10depicted in FIGS. 1-6; however, several additional optional features areprovided with respect to this embodiment. It should be appreciated thatany or all of these optional features can also be employed with thesystem 10 depicted in FIGS. 1-6 in any number of configurations.

An optional power supply 102 is preferably provided wherein the powersupply 102 is preferably in communication with the microwave generatorsystem 104, and more preferably with the microwave generator 106. Anoptional control system 108 is preferably provided wherein the controlsystem 108 is preferably in communication with the power supply 102,microwave generator system 104, and/or microwave generator 106. Anoptional temperature control system 110 is preferably provided whereinthe temperature control system 110 is preferably in communication withthe power supply 102, microwave generator system 104, microwavegenerator 106, and/or control system 108. Finally, an optional pyrometer112 is preferably provided wherein the pyrometer 112 cooperates with thelid member 114 such that the pyrometer is operable to detect, preferablyactively, the temperature of the material contained within the crucible116. The pyrometer 112 is preferably also in communication with thepower supply 102, microwave generator system 104, microwave generator106, control system 108, and/or temperature control system 110.

With respect to the operation of either system 10 and/or 100, it isintended that the material to be processed (e.g., melted) be acted uponby the microwave energy (e.g., heat) generated by the microwavegenerator. By way of a non-limiting example, the microwave generator ispreferably first actuated whereupon microwave energy is directed to thecoupler element (e.g., crucible) such that the coupler element begins toabsorb the microwave energy, whereupon the coupler element begins toheat up. As the coupler element begins to heat up, the radiant heat isat least partially absorbed by the material (e.g., a metal such asaluminum and alloys thereof, contained within the coupler element suchthat the material begins to also heat up. When the material reaches theapproximate halfway point of its melting point (which can preferably bedetermined by the pyrometer), either system 10 and/or 100 is preferablyoperable to couple directly to the material itself, that is, themicrowave energy is directly coupled to the material as opposed to thecoupler element. In this manner, the material is directly heated by themicrowave energy, as opposed to merely absorbing heat from the couplerelement.

This process can be automated wherein the microwave generator and itsassociated control systems can be pre-programmed to automatically switchthe coupling function when the material reaches the halfway meltingpoint. Thus, it is preferable to know the melting point of the materialprior to beginning the heating process. The melting points of mostmetals, and alloys thereof, are readily known in the art and will not bediscussed in detail herein. The microwave energy continues to bedirectly coupled to the material until it substantially melts, or untilsuch a point as circumstances require. The melted material can then beremoved from the coupler element, or alternatively, further processed.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

1. A die cast furnace system having a microwave energy source operablyassociated therewith, wherein the die cast furnace is selectivelyoperable to at least partially melt an amount of metal containedtherein.
 2. The invention of claim 1, further comprising a couplerelement operably associated with the die cast furnace system.
 3. Theinvention according to claim 2, wherein the coupler element is acrucible.
 4. The invention according to claim 3, wherein the crucible iscomprised of a ceramic material.
 5. The invention according to claim 4,wherein the ceramic material is comprised of silicon carbide.
 6. Theinvention according to claim 2, wherein the microwave energy source isselectively operable to heat the coupler element so as to at leastpartially melt an amount of metal contained therein.
 7. The inventionaccording to claim 6, wherein when the metal approximately attains halfof its melting point, the microwave energy source is selectivelyoperable to directly heat the metal so as to substantially fully meltthe metal.
 8. The invention according to claim 1, further comprising atemperature detection member operably associated with the die castfurnace system, wherein the temperature detection member is operable todetermine the temperature of the amount of metal.
 9. A die cast furnacesystem having a microwave energy source and coupler element operablyassociated therewith, wherein the die cast furnace is selectivelyoperable to at least partially melt an amount of metal containedtherein.
 10. The invention according to claim 9, wherein the couplerelement is a crucible.
 11. The invention according to claim 10, whereinthe crucible is comprised of a ceramic material.
 12. The inventionaccording to claim 11, wherein the ceramic material is comprised ofsilicon carbide.
 13. The invention according to claim 9, wherein themicrowave energy source is selectively operable to heat the couplerelement so as to at least partially melt an amount of metal containedtherein.
 14. The invention according to claim 13, wherein when the metalapproximately attains half of its melting point, the microwave energysource is selectively operable to directly heat the metal so as tosubstantially fully melt the metal.
 15. The invention according to claim9, further comprising a temperature detection member operably associatedwith the die cast furnace system, wherein the temperature detectionmember is operable to determine the temperature of the amount of metal.16. A die cast furnace system having a microwave energy source andcoupler element operably associated therewith, wherein the microwaveenergy source is selectively operable to heat the coupler element so asto at least partially melt an amount of metal contained therein, whereinwhen the metal approximately attains half of its melting point, themicrowave energy source is selectively operable to directly heat themetal so as to substantially fully melt the metal.
 17. The inventionaccording to claim 16, wherein the coupler element is a crucible. 18.The invention according to claim 17, wherein the crucible is comprisedof a ceramic material.
 19. The invention according to claim 18, whereinthe ceramic material is comprised of silicon carbide.
 20. The inventionaccording to claim 16, further comprising a temperature detection memberoperably associated with the die cast furnace system, wherein thetemperature detection member is operable to determine the temperature ofthe amount of metal.